Coaxial Cable Shield Structure for Small Diameter and Uniform Extrusion
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Solution Overview
Problem
Coaxial cables used in miniaturized electronic devices, such as those for 5G communication, face challenges with diameter reduction, appearance irregularities, and reduced shielding effectiveness due to gaps in lateral winding shields and air pockets during extrusion molding.
Innovation Solution
A coaxial cable design featuring a lateral winding shield with metal fine wires and a metal resin tape wound on the inside, where the metal resin tape is overlapped by a resin tape with an adhesive layer, reducing air pockets and maintaining electrical contact, and an extruded sheath is applied to minimize diameter fluctuations and enhance shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a lateral winding shield with fine wires is used to reduce diameter, then the cable diameter is reduced, but gaps occur between wires during wiring which reduces shielding effectiveness
Solution Approach 1:
The patent combines a lateral winding shield made of fine wires with a metal resin tape layer to create a composite shielding structure. The metal resin tape fills the gaps between the laterally wound fine wires, maintaining continuous shielding effectiveness while preserving the space-saving benefits of the lateral winding configuration. This composite approach allows the cable to achieve both small diameter and reliable shielding performance.
2Reliability
If metal resin tape is wound in layers to suppress shielding reduction, then shielding effectiveness is improved, but air pockets are trapped which cause appearance irregularities and diameter fluctuations
Solution Approach 1:
The patent specifies precise parameter ranges for the metal resin tape thickness (T1: 5-15 μm) and resin tape thickness (T2: 1-5 μm), with the ratio T2/T1 controlled between 0.15-0.50. By optimizing these dimensional parameters, the invention minimizes step formation and air pocket entrapment during extrusion molding, achieving both effective shielding and uniform cable appearance without requiring vacuum suction processes.
3Manufacturing precision
If vacuum suction is used during extrusion molding to remove air, then appearance irregularities are reduced, but processing complexity increases and yield still deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-coating the metal resin tape with a resin tape layer before extrusion molding. This preliminary coating creates a smooth, continuous surface that prevents air pocket entrapment during subsequent extrusion, eliminating the need for vacuum suction equipment and complex processing controls. The resin tape acts as a release layer that ensures uniform extrusion and consistent cable appearance.
4Manufacturing precision
If the resin tape thickness is increased to cover metal resin tape steps, then appearance uniformity is improved, but cable diameter increases
Solution Approach 1:
The patent optimizes the resin tape thickness parameter (T2: 1-5 μm) and controls the ratio T2/T1 between 0.15-0.50 to achieve the minimum necessary coverage of metal resin tape steps. This parameter optimization ensures appearance uniformity is improved while minimizing the increase in cable diameter, balancing both requirements through precise dimensional control.
Data Source
AI summary
To provide a coaxial cable with a favorable appearance and excellent processability. The above-described problem is solved by a coaxial cable comprising a center conductor (11), an insulator (12) provided on an outer periphery of the center conductor (11), an external conductor (13, 14) provided on an outer periphery of the insulator (12), and an outer coated body (15, 16) covering the external conductor (13, 14). The external conductor (13, 14) is constituted by a lateral winding shield (13) provided with metal fine wires laterally wound on the outer periphery of the insulator (12), and a metal resin tape (14) wound in a layer on the lateral winding shield (13) with a metal layer side being on an inside. The outer coated body (15, 16) is constituted by a resin tape (15) wound on the metal resin tape (14), and an extruded sheath (16) covering the resin tape (15). Given T1 as a thickness of the metal resin tape (14) and T2 as a thickness of the resin tape (15), T2/T1 is within a range from 0.180 to 0.800.